What would your opinion be about a block that comes from the Bug Shop? The
guy I talked to there says they have rebuilt thousands of these engines over
many years, and that the block would come with a warranty if they do the
work. In terms of my goals, I want to go on a long trip with my wife next
year for about 6-8 months, and after that I probably will sell the van when
we move aboard our sailboat. Although I got the van for a very good price,
I'm wary of spending 3 grand on a long block for one season. But like you
say, I could keep pumping money into it if I don't go the smart route. And I
don't want to be left stranded on the side of the road, either.

On 10/18/06 5:42 PM, "Dennis Haynes" <dhaynes@optonline.net> wrote:

> Very few of these engine cases are reusable. VW often considered these cases
> as consumable and factory rebuilds often had new cases. A recent water boxer
> I installed even had a new case. Rebuilt heads but new case. You can keep
> spending money thinking you are saving but until you really know what to
> look for, you will do this many times.
>
> My suggestion is to get a completely rebuilt long block with a warranty.
> Since you can at least do the install, you can save some funds there. Try to
> get a warranty that includes some labor compensation. Understand that most
> of these rebuilds will have welded and re-machined parts. These engines in
> general just do not have long life spans. Yes, some have gotten good service
> out of them but they are prone to overheating and the stud pulling, case
> twisting that comes with it.
>
> Dennis
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> Nathaniel Poole
> Sent: Wednesday, October 18, 2006 7:43 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: <no subject>
>
> SO I got the engine out and flywheel off (needs a new flywheel), heads and
> cylinders off. Unfortunately Dennis was right about the block - the rear
> thrust bearing is moving in its seat, I can rotate it about 1/8" inch.
> Nobody in Vancouver area can machine these blocks and there isn't an
> oversize bearing available, so it looks like a new used block for me. I'm
> leaning towards letting the machine shop do the parts swap - polish the
> crank, mic everything, install new bearings, probably new cam and lifters. I
> could do this part myself and save $400 bucks but the chances of fouling up
> something are good as I have NO experience with these engines. It's weird,
> this engine was rebuilt not that long ago from all appearances - no cylinder
> ridge and you can still see the crosshatch marks on the cylinder walls, oil
> galleries drilled and plugged. I know the heads were rebuilt this summer.
> Yet all told I'm still looking at a grand, not including new exhaust and
> heqter boxes, and I'm still left with a questionable motor. So now I'm
> wondering what one of these engine conversions cost?
>